Disassembly
Precaution1. Clean the transaxle exterior thoroughly with steam or cleaning solvents before disassembly.
2. Clean the removed parts with cleaning solvent, and dry with compressed air. (Except sealed bearings.) Clean out all holes and passages with compressed air, and check that there are no obstructions.
3. Wear eye protection when using compressed air to clean components.
Step 1
1. Rear cover
2. Roll pin
3. Locknut
4. Locknut
5. Primary reverse synchronizer gear and gear sleeve
6. Synchronizer ring
7. Secondary reverse synchronizer gear
8. Shift fork (5th/Rev.)
9. Clutch hub assembly (5th/Rev.)
10. Synchronizer ring
11. 5th gear
12. Secondary 5th gear
13. Needle bearing
14. Gear sleeve
15. Ball
16. Interlock plate
17. Interlock pins
18. Reverse switch
19. Bolt(s), spring(s) and ball(s)
20. Transaxle case
21. Magnet
22. Reverse idle shaft
23. Reverse idle gear
24. Snap ring
25. Washer
26. Needle bearings
27. Base plate unit
28. Crank lever shaft and snap ring
29. Crank lever assembly
30. Roll pin
31. Shift rod (1st/2nd)
32. Shift fork (1st/2nd)
33. Roll pin
34. Roll pin
35. Shift rod (3rd/4th)
36. Shift fork (3rd/4th)
37. Shift rod end (3rd/4th)
38. Roll pin
39. Shift rod (5th/Rev.)
40. Shift rod end (5th/Rev.)
41. Primary shaft gear assembly
42. Secondary shaft gear assembly
43. Differential assembly
44. Reverse shift lever
46. Neutral switch
47. Clutch housing
48. Drain plug
49. Interlock pin
50. Synchronizer key spring
51. Clutch hub sleeve
52. Synchronizer key
53. Clutch hub
1. Disassemble in the order shown in the image, referring to Disassembly Note.
Preinspection
5th gear thrust clearance
1. Measure the 5th gear thrust clearance with a dial indicator.
Clearance: 0.150-0.262 mm (0.0059-0.0103 in)
Maximum: 0.262 mm (0.0103 in)
2. If the clearance exceeds the maximum, check the contact surfaces of 5th gear and the clutch hub. Replace worn or damaged parts.
Disassembly note
Transaxle
Mount the transaxle on the SST.
Roil pin
Remove the roll pin with pin punch.
Locknut
1. After removing the roll pin, shift the gears to 5th gear.
2. Shift the gears to 1st gear.
3. Remove the locknuts.
CAUTION: Uncrimp the tab of the locknuts.
Shift Fork (5th)
Remove the shift fork (5th) together with the clutch hub assembly.
Bolts, Springs and Balls
1. Remove the bolts, springs and balls.
2. Remove the transaxle case installation bolts, and remove the transaxle case.
Step 2
1. Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Bearing outer race (differential)
Remove the baring outer races with the SST.
Bearing outer race and funnel (secondary shaft gear; clutch housing)
Remove the bearing outer race by lifting the funnel and the race out together.
Change rod
Remove the roll pin with pin punch.
On-vehicle replacement
Oil seals
Jack up the vehicle, support it on safety stands, and then drain the transaxle oil. Next, use the following procedure to replace the driveshaft oil seals:
1. Remove the front wheel(s).
2. Remove the splash shield(s).
3. Separate the front stabilizer from the lower arm.
4. Remove the clinch bolt and pull the lower arm downward. Separate the knuckle from the lower arm ball-joint.
NOTE: Be careful not to damage the ball-joint dust boot.
5. Remove the cotter pin then disconnect the tie-rod end with the SST.
CAUTION
- Do not damage the oil seal.
- Do not separate the driveshaft by pulling the disc plate.
6. Separate the left driveshaft from the transaxle by prying with a bar inserted between the shaft and the case.
7. Remove the oil seal with a flat-tipped screwdriver.
8. Tap the new oil seal into the transaxle case with the SST.
NOTE
- Tap in until the oil seal installer contacts the case.
- Coat the oil seal lip with transaxle oil.
9. Replace the driveshaft end clip with a new one. Insert the clip with the gap at the top of the groove.
10. Install the driveshaft as follows:
1. Pull the front hub outward, then fit the driveshaft into the transaxle.
2. Insert the driveshaft into the transaxle by pushing on the wheel hub assembly.
NOTE
- Be careful not to damage the oil seal.
- After installation is finished, pull the front hub slowly outward to check that the driveshaft is held securely by the clip.
11. Install the lower arm ball-joint to the knuckle, and tighten the clinch bolt.
Tightening torque: 43-54 N.m (4.4-5.5 m-kg, 32-40 ft-lb)
12. Install the tie-rod end and new cotter pin.
Tightening torque: 29-44 N.m (3.0-4.5 m-kg, 22-33 ft-lb)
13. Adjust and tighten the stabilizer.
Tightening torque: 16-23 N.m (1.6-2.3 m-kg, 12-17 ft-lb)
Dimension: 20.1 ± 2 mm (0.79 ± 0.08 in)
14. Install the drain plug.
Tightening torque: 39-59 N.m (4.0-6.0 m-kg, 29-43 ft-lb)
15. Install the wheel.
Tightening torque: 88-118 N.m (9.0-12.0 m-kg, 65-87 ft-lb)
16. Add the correct quantity of the specified oil.
Type:
All-season SAE 75W-90 ATF: DEXRON-II
Above -18 °C (0 °F):
API: GL-4 or GL-5
SAE 80W-90 or SAE 90
Capacity: 3.65 liters (3.9 US qt, 3.2 Imp qt)
Step 3
1. Disassemble in the order shown in the image, referring to Disassembly Note.
Disassembly note
Primary shaft gear
Bearing Inner race (primary 4th gear end)
Remove the bearing inner race and 4th gear with the SST.
CAUTION: Hold the shaft with one hand so that it does not fall.
Clutch hub assembly (3rd/4th)
Remove the 3rd gear and clutch hub assembly with the SST.
Bearing inner race
Remove the bearing inner race with the SST.
CAUTION: Hold the shaft with one hand so that it does not fall.
Secondary shaft gear
Bearing Inner race (secondary 4th gear end)
Remove the bearing and secondary 4th gear with the SST.
CAUTION: Hold the shaft with one hand so that it does not fall.
Clutch hub assembly and primary 1st gear
Remove the clutch hub assembly (1st/2nd) and 1st gear.
CAUTION: Hold the shaft with one hand so that it does not fall.
Bearing inner race
1. Set the SST to the bearing inner race as shown.
2. Remove the bearing inner race with the SST.
CAUTION: Hold the shaft with one hand so that it does not fall.
Step 4 (Differential)
1. Inspect side gears and pinion gears for backlash, referring to Preinspection.
CAUTION: Do not remove inner races if not necessary.
2. Disassemble in the order shown in the image, referring to Disassembly NOTE.
Preinspection
Backlash
Before disassembly, check the backlash of the side gears and pinion gears.
If not, repair or replace as necessary.
Standard backlash: 0-0.1 mm (0-0.004 in)
Disassembly note
Roll pin
To remove the roll pin from the pinion shaft, place the gear case in a vise and knock the pin out.
NOTE: insert the rod into the roll pin hole from the ring gear mounting surface side.
Side bearing inner race (side opposite ring gear)
Remove the bearing inner race with the SST.
CAUTION: Hold the gear case with one hand so that it does not fall.
Side bearing inner race (ring gear side)
Remove the bearing inner race with the SST.
NOTE: Use pads in the vise.